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  SAFE Home
Home >>Guidelines >>Safety Code Of Practice For CNG Buses >>Checklist - Third party Checking
 

This checklist is for third party inspection of fully built CNG buses before registration by RTOs. Reference to relevant clauses of Safety Code of Practice, e.g.AIS 028, and guidelines issued by Central Government from time to time should be made wherever appropriate.

The vehicle being offered for third party inspection must be thoroughly cleaned before hand.

  • Name and address of chassis manufacturer/Retrofitter
  • Name of type approval agency
  • Details of type approval certificate
    • Certificate No.
    • Date of Issue
    • Valid till
  • Name and address of bus body builder
  • Name and address of approved inspecting agency, prior to registration
  • Chassis and engine No.
  • Year of manufacture
  • Checking of Cylinders as per DOE/ vehicle testing agency approvals
    1. Validity of DOE Certificate
      • Certificate No:
      • Date of Certificate
      • Date of Expiry
    2. Safety checks
      • Check for corrosion on any CNG components / mountings of gas circuit
      • Ensure cylinder is securely mounted within the vehicle and check tightness of nuts and bolts
      • Ensure minimum 5 mm clearance is kept between cylinders and vehicle body structure
      • Distance between fuel line and exhaust heat source shall not be less than 75 mm
      • Distance between cylinder valve and bus body extremities shall not be less 200 mm
  • Cylinder Valves
    • Approval from DOE
    • Check for Shield / protection and physical damage to valves
    • Leak Test using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • Refilling Valve
    1. Safety checks
    • Check for dust cap / plug
    • Check that engine should not start when dust cap / plug is removed or open
    • Check leakage for non-return valve using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action.
  • Fuel Line
    1. Safety checks
    • Check for corrosion on CNG fuel line
    • Ensure fuel line is securely mounted
    • Check U and Pigtail bends provided in high pressure piping for flexibility as per approved layout
    • Leak Test using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action.
  • Shut Off Valve (Solenoid Valve(s)) wherever separately provided
    1. Safety checks
    • Ensure shut off valve is securely mounted
    • Check operation for "Close & Open" as required. If necessary use 'noise stethoscope'
    • Leak Test using Methane Leak Detector and then use non corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • Regulator
    1. Safety checks
    • Ensure regulator is securely mounted
    • Leak Test using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • Gas-Air Mixer
    1. Safety checks
    • Ensure gas-air mixer is securely mounted
    • Leak Test using Methane Leak Detector and then use non- corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • Electrical wiring
    1. Safety checks
    • Ensure that current limiting device (fuse) is CNG Filter: fitted as per chassis manufacturer's - Distance specifications and make - Ensure CNG filter is securely mounted
    • Check wiring harness layout under the floor and in the engine compartment to be in accordance with chassis manufacturer's layout /specifications / approval
    • Check wiring harness in cabin and passenger compartment to be as per chassis manufacturer's guidelines / approval
    • Terminals are insulated to prevent shorting
    • Wiring are taped and clipped with loom & mounted securely
    • Cable harness has to be as per the recommendations of OE chassis/ vehicle manufacturers
    • Battery terminal has to have a positive locking
    • Check installation of battery cut-off switch as per chassis manufacturer's recommendations
    • Check routing of high tension cable to avoid accidental earthing and to be placed away from any heat source - as per chassis manufacturer's recommendations/ layout
    • Check for proper make of high tension cable as per chassis manufacturer's recommendation as well as check for tight fitment of its terminal to the spark-plug
  • Service shut-off valve:
    1. Safety checks
    • Check operation
    • Ensure service shut off valve is securely mounted
    • Leak Test using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • CNG Filter
    • Distance
    • Ensure CNG filter is securely mounted
    • Leak Test using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • NG Pressure Gauge
    • Ensure CNG pressure indicator is not loose
    • Leak Test using Methane Leak Detector and then use non-corrosive foaming agent on the identified points of leakage for confirmation and corrective action
  • Compliance Plate:
    • Installation Check
    • Check for following
    • Cylinder identification No.
    • Date of installation
    • Water capacity (1tr) of total installation
    • Date of last reset
    • Vehicle registration/ identification No. (to be furnished after registration)
    • Seal of the checking /inspection agency
  • Identification label in front and rear
    • Located on left side of the front and rear safety glass and shall ensure visibility from front and rear sides
  • Following additional points are to be complied at the time of registration of CNG vehicle for enhancement of safety of vehicle.
    • Fire retardant material shall be used for seat/ upholstery/roof & side lining as per manufacturer's and bus body builder's specification.
    • One number each of dry powder type fire extinguishers (2 kg) shall be provided in driver's and passenger's compartment.
    • For servicing of CNG vehicle proper instructions, detailed operational & service manual with DOs & DON'Ts shall be provided by chassis manufacturer and body builder. Vehicle / chassis manufacturer should devise training module and impart training to drivers and technicians for safe operation of CNG system.
    • Check for First-Aid kit as per CMVR.
    • Buses should be properly maintained and checked every day before starting and bringing on road.
    • Minimum two copies of safety instructions shall be displayed in passenger's compartment.
    • Check for proper venting provided by louvers / holes / mesh on the side skirt as per Vehicle Manufacturer's drawing so that in case of any leakage the entrapped gas under the floor escapes to the atmosphere.
    • The bus body builder to provide at least two (total minimum area of 550 sq. mm) vent pipes connecting the under floor of the bus to the rooftop for CNG gas to vent out in case of leakage. The vent pipes to be located close to the cylinder valves cluster as per recommendations of chassis manufacturer. Construction should be such that leakage into passenger compartment is avoided.
    • Any other safety recommendations provided or advised by the chassis manufacturers to be complied with.

    Note: The instructions issued by OE manufacturer/ retrofitter for third party evaluation, in their instruction manual, shall contain all the necessary details on the methodology & the procedure for carrying out these checks.

    Authorised Signatory: Signature & Seal with date

 
 
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